High-resolution 3D Printing Technology Research Articles

Advanced Nanomaterials in Medical 3D Printing.

3D printing is now recognized as a significant tool for medical research and clinical practice, leading to the emergence of medical 3D printing technology. It is essential to improve the properties of 3D-printed products to meet the demand for medical use. The core of generating qualified 3D printing products is to develop advanced materials and processes. Taking advantage of nanomaterials with tunable and distinct physical, chemical, and biological properties, integrating nanotechnology into 3D printing creates new opportunities for advancing medical 3D printing field. Recently, some attempts are made to improve medical 3D printing through nanotechnology, providing new insights into developing advanced medical 3D printing technology. With high-resolution 3D printing technology, nano-structures can be directly fabricated for medical applications. Incorporating nanomaterials into the 3D printing material system can improve the properties of the 3D-printed medical products. At the same time, nanomaterials can be used to expand novel medical 3D printing technologies. This review introduced the strategies and progresses of improving medical 3D printing through nanotechnology and discussed challenges in clinical translation.

Characterization of a 30 µm pixel size CLIP-based 3D printer and its enhancement through dynamic printing optimization.

Resolving microscopic and complex 3D polymeric structures while maintaining high print speeds in additive manufacturing has been challenging. To achieve print precision at micrometer length scales for polymeric materials, most 3D printing technologies utilize the serial voxel printing approach that has a relatively slow print speed. Here, a 30-µm-resolution continuous liquid interface production (CLIP)-based 3D printing system for printing polymeric microstructures is described. This technology combines the high-resolution from projection microstereolithography and the fast print speed from CLIP, thereby achieving micrometer print resolution at x103 times faster than other high-resolution 3D printing technologies. Print resolutions in both lateral and vertical directions were characterized, and the printability of minimum 30 µm features in 2D and 3D has been demonstrated. Through dynamic printing optimization, a method that varies the print parameters (e.g. exposure time, UV intensity, and dark time) for each print layer, overhanging struts at various thicknesses spanning 1 order of magnitude (25 µm - 200 µm) in a single print are resolvable. Taken together, this work illustrates that the micro-CLIP 3D printing technology, in combination with dynamic printing optimization, has the high resolution needed to enable manufacturing of exquisitely detailed and gradient 3D structures, such as terraced microneedle arrays and micro-lattice structures, while maintaining high print speeds.

High‐Resolution 3D Printing for Electronics (Adv. Sci. 8/2022)

Printed Electronics Recent progress in electronics has expanded their applicability in various fields in which structural conformability and 3D configuration are required. High-resolution 3D printing technologies for forming dynamic electronic structures are of increasing interest. More details can be found in article number 2104623 by Jang-Ung Park and co-workers.

High-Resolution 3D Printing for Electronics.

The ability to form arbitrary 3D structures provides the next level of complexity and a greater degree of freedom in the design of electronic devices. Since recent progress in electronics has expanded their applicability in various fields in which structural conformability and dynamic configuration are required, high‐resolution 3D printing technologies can offer significant potential for freeform electronics. Here, the recent progress in novel 3D printing methods for freeform electronics is reviewed, with providing a comprehensive study on 3D‐printable functional materials and processes for various device components. The latest advances in 3D‐printed electronics are also reviewed to explain representative device components, including interconnects, batteries, antennas, and sensors. Furthermore, the key challenges and prospects for next‐generation printed electronics are considered, and the future directions are explored based on research that has emerged recently.

Polymer architecture as key to unprecedented high-resolution 3D-printing performance: The case of biodegradable hexa-functional telechelic urethane-based poly-ε-caprolactone

Two-photon polymerization (2PP) is a high-resolution 3D-printing technology with a very rapidly expanding field of applications, including tissue engineering (TE). In this field, 2PP offers unprecedented possibilities for systematic studies of both cell–cell and cell–material interactions in 3D. For TE applications, the reliable production of biodegradable micro-scaffolds in porous, complex architectures is essential. However, the number of biodegradable materials that support the required level of spatial resolution is very limited, being a major bottleneck for the use of 2PP in the TE field.Herein, we introduce a hexa-functional urethane-based biodegradable precursor that overcomes the limitations associated with the high-resolution printing of current biodegradable precursors. The precursor is a telechelic urethane-based poly-ε-caprolactone (PCL) possessing three acrylate functionalities at each polymer end group which enables the reliable production of complex architectures owing to its superior physical properties as compared to the traditional di-acrylate terminated analogs. The newly developed hexa-functional telechelic urethane-based PCL reveals enhanced crosslinking kinetics and one order of magnitude higher Young’s modulus compared to the di-functional precursor (57.8 versus 6.3 MPa), providing an efficient and solvent-free 2PP processing at fast scanning speeds of up to 100 mm s−1 with unprecedented feature resolutions (143 ± 18 nm at 100 mm s−1 scanning speed). The crosslinked hexa-functional polymer combines strength and flexibility owing to the segregation between its hard polyacrylate and soft PCL segments, which makes it suitable for biological systems in contrast to the highly crosslinked and rigid structures typically manufactured by 2PP. Furthermore, it revealed lower degradation rate compared to its di-functional analog, which can be considered as an advantage in terms of biocompatibility due to the slower formation of acidic degradation products. Extracts of the developed polymers did not show a cytotoxic effect on the L929 fibroblasts as confirmed via ISO 10993-5 standard protocol. The presented precursor design constitutes a simple and effective approach that can be easily translated towards other biodegradable polymers for the manufacturing of biodegradable constructs with nano-scale precision, offering for the first time to use the true capabilities of 2PP for TE applications with the use of synthetic biodegradable polymers.

3D-Printed Flow Cells for Aptamer-Based Impedimetric Detection of E. coli Crooks Strain.

Electrochemical spectroscopy enables rapid, sensitive, and label-free analyte detection without the need of extensive and laborious labeling procedures and sample preparation. In addition, with the emergence of commercially available screen-printed electrodes (SPEs), a valuable, disposable alternative to costly bulk electrodes for electrochemical (bio-)sensor applications was established in recent years. However, applications with bare SPEs are limited and many applications demand additional/supporting structures or flow cells. Here, high-resolution 3D printing technology presents an ideal tool for the rapid and flexible fabrication of tailor-made, experiment-specific systems. In this work, flow cells for SPE-based electrochemical (bio-)sensor applications were designed and 3D printed. The successful implementation was demonstrated in an aptamer-based impedimetric biosensor approach for the detection of Escherichia coli (E. coli) Crooks strain as a proof of concept. Moreover, further developments towards a 3D-printed microfluidic flow cell with an integrated micromixer also illustrate the great potential of high-resolution 3D printing technology to enable homogeneous mixing of reagents or sample solutions in (bio-)sensor applications.

Characterization of a customized 3D-printed cell culture system using clear, translucent acrylate that enables optical online monitoring

Cells are very sensitive to their direct environment—they place high demands, for example, on ambient culture medium, adjacent cell types, and the properties of surrounding material parts. As a result, mechanical and physical material properties—such as surface roughness, swelling, electrostatic effects, etc—can all have a significant impact on cell behaviour. In addition, a material’s composition also impacts whether that material meets biocompatibility requirements and can thus be considered for potential use in biomedical applications. The entry of high-resolution 3D printing technology in biotechnology has opened the door to individually-designed experiment-adaptable devices of almost unlimited complexity that can be manufactured within just a few hours. 3D printing materials are frequently lacking in the characteristics that make them suitable for biomedical applications, however.This study introduces a high-resolution polyacrylic 3D printing material as a potential alternative material for use in cultivation systems with indirect or direct contact to cells. Viability analyses, studies of apoptotic/necrotic cell death response, and surface studies all suggest that this material meets the requirements for (in vitro) biocompatibility, and has surface properties sufficient to permit uninhibited cell proliferation for cells in direct contact to the material. Moreover, the translucency of this material facilitates the type of optical monitoring required for performing experiments in a microfluidic environment, or for facilitating microscopic observations.

Designing stress for optimizing and toughening truss-like structures

Optimization of materials and structures is a crucial step in the design of man-made mechanical components for a wide field of engineering applications. It also plays a key role in mechanobiology of living systems, being involved by nature across the scales, from single-cell to tissues and organs, as a strategy to minimize metabolic cost and maximize biomechanical performances. The synergy between the continuously increasing development of high-resolution 3D printing technologies and the possibility to predict chemical and physical properties through molecular dynamics-based numerical analyses has recently contributed to boost the use of both design and topology optimization procedures. They are employed in ab initio simulations as key strategies for deciding microstructures to improve mechanical performances and, concretely, to achieve prototypes of new material components. With this in mind, we here propose to abandon the classical approach of using a single scalar objective function employed in the classical design and topology optimization strategies, to introduce multiple quantities to be minimized, identified as the differences between material yield stress and the maximum von Mises stress. After mathematically justifying the well-posedness of this unconventional choice for the case at hand, it is highlighted that the proposed strategy is based on the concept of "equalizing" a proper stress measure at any point of the body and, for this reason, it is baptized as Galilei’s optimization, in honor of the Italian scholar who somehow first wondered about the possibility of changing sizes of beams to have uniform internal forces and, in turn, minimum weight. By exploiting analytical solutions and ad hoc implementing a parametric finite element algorithm to be applied to a wide variety of solids with arbitrary complex structural geometries, including nested or hierarchically organized architectures, it is first demonstrated that the proposed optimization strategy roughly retraces principles invoked by nature to guide growth, remodeling and shaping of biomaterials. More importantly, by means of several benchmark examples, we finally show the proposed procedure might be also helpfully employed to conceive a new class of micro-structured, eventually 3D-printed materials exhibiting surprising post-elastic properties, such as high overall resilience and toughness, in particular obtaining a decrease of stress concentration and a slowing down of crack propagation as direct effects of the optimization, which de facto minimizes stress gradients wherever in the solid domain.

Emerging Technologies and Materials for High-Resolution 3D Printing of Microfluidic Chips.

In recent years, 3D printing has had a huge impact on the field of biotechnology: from 3D-printed pharmaceuticals to tissue engineering and microfluidic chips. Microfluidic chips are of particular interest and importance for the field of biotechnology, since they allow for the analysis and screening of a wide range of biomolecules - including single cells, proteins, and DNA. The fabrication of microfluidic chips has historically been time-consuming, however, and is typically limited to 2.5 dimensional structures and a restricted palette of well-known materials. Due to the high surface-to-volume ratios in microfluidic chips, the nature of the chip material is of paramount importance to the final system behavior. With the emergence of 3D printing, however, a wide range of microfluidic systems are now being printed for the first time in a manner that facilitates flexibility while minimizing time and cost. Nevertheless, resolution and material choices still remain challenges and in the focus of current research, aiming for (1) 3D printing with high resolutions in the range of tens of micrometers and (2) a wider range of available materials for these high-resolution prints. The first part of this chapter highlights recent emerging technologies in the field of high-resolution printing via stereolithography (SL) and 2-photon polymerization (2PP) and seeks to identify particularly interesting emerging technologies which could have a major impact on the field in the near future. The second part of this chapter highlights current developments in the field of materials that are used for these high-resolution 3D printing technologies.

A Quantitative Perceptual Model for Tactile Roughness

Everyone uses the sense of touch to explore the world, and roughness is one of the most important qualities in tactile perception. Roughness is a major identifier for judgments of material composition, comfort, and friction, and it is tied closely to manual dexterity. The advent of high-resolution 3D printing technology provides the ability to fabricate arbitrary 3D textures with surface geometry that confers haptic properties. In this work, we address the problem of mapping object geometry to tactile roughness. We fabricate a set of carefully designed stimuli and use them in experiments with human subjects to build a perceptual space for roughness. We then match this space to a quantitative model obtained from strain fields derived from elasticity simulations of the human skin contacting the texture geometry, drawing from past research in neuroscience and psychophysics. We demonstrate how this model can be applied to predict and alter surface roughness, and we show several applications in the context of fabrication.

Reprocessable thermosets for sustainable three-dimensional printing

Among all three-dimensional (3D) printing materials, thermosetting photopolymers claim almost half of the market, and have been widely used in various fields owing to their superior mechanical stability at high temperatures, excellent chemical resistance as well as good compatibility with high-resolution 3D printing technologies. However, once these thermosetting photopolymers form 3D parts through photopolymerization, the covalent networks are permanent and cannot be reprocessed, i.e., reshaped, repaired, or recycled. Here, we report a two-step polymerization strategy to develop 3D printing reprocessable thermosets (3DPRTs) that allow users to reform a printed 3D structure into a new arbitrary shape, repair a broken part by simply 3D printing new material on the damaged site, and recycle unwanted printed parts so the material can be reused for other applications. These 3DPRTs provide a practical solution to address environmental challenges associated with the rapid increase in consumption of 3D printing materials.

Push-to-pull tensile testing of ultra-strong nanoscale ceramic–polymer composites made by additive manufacturing

The search for light yet strong materials recently benefited from novel high resolution 3D-printing technologies, which allow for fabricating lightweight porous materials with optimally designed micro-topologies. Architectural design improves mechanical properties significantly compared to stochastic porosity, as in foams. Miniaturization of the architectures offers to exploit material strengthening size-effects occurring at the nanoscale. However, these effects and their interaction with structural behavior are not yet well understood. We present tensile experiments of nanoscale alumina–polymer composite bars and cellular microarchitectures, applying 3D-printed push-to-pull mechanisms. The strength of alumina is found to strongly increase as the material thickness decreases. Below 50 nm thickness a plateau at about 5.5 GPa is reached, which is in the range of the theoretical strength. The characteristic low tensile strength of ceramics and its high variability seem not to hold at the nanoscale. Thus, when designed and fabricated appropriately, microarchitectures will facilitate carrying these size-effects beyond scales in future, allowing the use of ceramic materials far beyond what is possible to date.